International Journal of Trend in Scientific Research and Development (IJTSRD)
Volume 4 Issue 5, July-August 2020 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470
Improvement in Productivity by Lean
Approach Method in Amararaja Industries
R. V. Vijayendar Reddy1, N. Phani Raja Rao2, K. Pavan Kumar Reddy3
1Research
Scholar [M. Tech-Production Engineering], 2Assistant Professor, 3Head of the Department,
1,2,3Department of Mechanical Engineering, Sri Venkateswara Institute of Technology,
Affiliated to JNTU University, Hampapuram (v), Rapthadu (m), Anantapuramu, Andhra Pradesh, India
ABSTRACT
To survive in the market, the goal of any manufacturing industry is to produce
goods at the lowest time and lowest cost possible. To attain this lean approach
improves productivity systems by manufacturing without wastes. The purpose
of this project work is to improve production system in assembly section and
finishing section at the Amara raja batteries, Tirupathi. In the finishing section
the cycle time is reduced from 103 sec to 68 sec and production rates is
increased from 245 skids/shift to 371 skids/shift. The fatigue of workers also
reduced by adapting belt conveyor system.
How to cite this paper: R. V. Vijayendar
Reddy | N. Phani Raja Rao | K. Pavan
Kumar
Reddy
"Improvement
in
Productivity by Lean Approach Method in
Amararaja Industries" Published in
International Journal
of Trend in Scientific
Research
and
Development (ijtsrd),
ISSN:
2456-6470,
Volume-4 | Issue-5,
August
2020,
IJTSRD33054
pp.1165-1167, URL:
www.ijtsrd.com/papers/ijtsrd33054.pdf
KEYWORDS: Lean approach, RPW method, Assembly section, finishing section
Copyright © 2020 by author(s) and
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INTRODUCTION
Production is the sequence of operations which transform
the given materials into desired products. This
transformation from one form to another is carried out
either by one or a combination of different manufacturing
processes. A system is a logical arrangement of components
(physical and conceptual) designed to achieve objectives
according to a plan.
IN

MATERIAL

LABOUR

MACHINE
OUT 
CONVERSION
PROCESS
A production system is the framework within which the
conversion of input into output occurs. At the one end of the
production system are the inputs and the other end outputs.
Inputs and outputs are linked by certain operations or
processes which impart value to the inputs and are called
transformation process.
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Objective of the project:
To improve production system in SBD assembly section at
AMARA RAJA BATTERIES Ltd, Tirupathi by applying lean
manufacturing technique. Lean manufacturing mean
manufacturing without wastes. In the assembly section the
cycle time is reduced from 15.00 sec/battery to 12.50
sec/battery and production rate is increased 1680
batteries/shift to 2018 batteries/shift.
LINE BALENCING
Chapter is to explore and gathered all information in order
to understand clearly about the balancing. The information is
come from reference books, journals and thesis. The
structure of this chapter is show in the fig. these sections are
mainly concern about related knowledge about line
balancing. Small and medium industries becoming the
selected area then the scope is narrow down from manually
assembly line through down until last part in productivity.
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International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
Six sigma:
Six sigma at many organizations simply means a measure of
quality that strives for near perfection.
Six sigma is a disciplined data driven approach and
methodology for eliminating defects from manufacturing to
transactional and from product to services.
Six sigma aims to deliver "breakthrough performance
improvement" from current level in business and customer
relevant operational and performance measures.
Six sigma black belt method is one of the operational
methodologies in six sigma. This process is used in to
improve the productivity SBD assembly section in Amara
raja batteries limited.
Six sigma black belt will provide the valuable skills used to
tackle the toughest problem confronting the organization.
The black belt methodology composed of five phases each
bear the acronyms DMAIC and DMADV.
RANKED POSITIONAL WEIGHT METHOD:
Ranked positional weight method (RPW) was introduced by
Helgeson and Bernie in 1961, which it’s value to be
computed for each element in the system. The RPWfor each
TeK and its position on the raw chain in the precedent
diagram. TeK is a time to perform work element k, minute
and hence thes values of Tek are additives.
Lean approach method
Inspired from the Japanese management methods, and more
specifically, the Toyota Production System, the LEAN
approach is intended to have the enterprise think first and
foremost about maximizing the value that its products and
services can bring to the client.
Six sigma is one of the lean approach method to increase the
production rate of plant.
The ranked positional weight method used and computed
for each element. The method accounted for TeK value and its
position in the precedence diagram. The RPWk is calculated
by summing TeK and the other times for elements that follow
TeK in the arrow chain of the precedence diagram table.
Assignment of elements to stations proceeds with the
solution is shown in figure. The idle time was determined to
be zero second for station 2 with 1, 5 and 3 seconds for
stations 1, 3 and 4 respectively, in this case, station 2 is the
bottleneck station.
WORK ELEMENTS ARRANGED ACCORDING TO TEk VALUES FOR THE RPW
WORKSTATIONS:
Sequence of operation
Name of activity
Function
1
Cell insertion
To be insert in to Rack
2
OCV checking
To know the OCV of the cell
3
Resin pouring
Resin -for Know positive And negative terminal
4
Apply methanol
Lubricant for Hardware
5
Putting hardware
Hardware fixing
6
Fixing hardware
Hardware removing
7
Hardware removal
Remove hardware
8
Cleaning with thinner
For Cleaning
9
Number punching activity
Final punching -what is the code represents
10
Traceability
What is updating in traceability
11
CR plate
Supporting frame for the cell
12
Hardware Fixing-CR plate
Hardware fixing
13
Tightened-CR plate
Tightening
14
Moved to dispatch
The total time for producing one battery is 1680/60=28 mins
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International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
Assembly section Result
Shift Time
Lunch time
Tea time
Actual available time
No of components produced per shift
No of persons used per shift
cycle time per Battery
Productivity
proposed System:
No of components produced per shift
No of components produced extra
Cycle time per battery
Productivity
S. No
1
2
3
Description
Manpower
Movement
Equipment
480
45
15
420
1680
01
15
4
Min
Min
Min
Min
Batteries
Person
Sec
Batteries/Mint
2028
348
12.42
4.83
Units
comp/shift
Sec
Batteries/Mint
Productivity matrix
Present Proposed Savings
20
11
9
17885
5390
12495
2
0
2
CONCLUSIONS
In assembly section the proposed system is developed by Six
Sigma Method. The cycle time is very much reduced. So, the
productivity of the assembly section is increased.
In finishing section, the proposed Layout is developed by
RPW Method. The cycle time is very much reduced. The no of
workers required are also reduced per shift. The fatigue of
workers is also reduced by adopting conveyor for material
handling.
By adopting both proposed assembly section and proposed
finishing section the productivity of the organization will be
increased. The company can get more profit if assembly
section and finishing sections are modified.
In assembly section the savings may be around 15 Lakhs per
year and in finishing section the savings may be around 35
Lakhs per year. The total savings may be around 50 Lakhs
per year.
UOM
No of persons
No of meters/shift
Fork lift
REFERENCES
[1] The lean six sigma black belt hand book: -Frank Voehl
& H. James Harrington
[2] Productivity improvement through line balancing: HazmilbilHapaz
[3] Operations Management by: - Jey Heizer and Barry
Render
[4] Operation Research: - Dr. R. K. Gupta
[5] Industrial engineering: - M. I. Khan
[6] Introduction to Work-study: - George Kanawaty
[7] Lean Manufacturing: -Arvindh,B. and Irani.
[8] Operations management: -H. Jay and R.Barry,2006
OTHER WEBSITES:[1] www.google.com
[2] www.wikipedia.com
[3] www.bingo.com.
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Unique Paper ID – IJTSRD33054
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Volume – 4 | Issue – 5
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July-August 2020
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